Metal repair device



P 1960 D. DIPERSTEIN 2,951,5'fi3 METAL REPAIR DEVICE} Filed May 19, 1959 INVENTOR. 0A V/D D/Pf/b TH V 119.2 MM/{S M 2,951,506 9 Patented Sept-6,1969

The present invention relates to a metal repair device, and more particularly to a device for repairing cracks or breaks in cast metals. 9 h h To repair a break or crack in a cast metal article, it is necessary to mechanically connect the sides of the break or crack to prevent the break or crack from increasing in size and spreading along the cast metal article. Further- 9 more, when the break or crack is in a cast metal pipe or tank, it is also necessary toseal the break or crack to prevent the material contained in the pipe or tank from flowing through the break or crack. 99

'Heretofore, breaks or cracks in acast metal article have been repaired by cutting a plurality of elongated, variable width grooves in the outer surface of the metal article at spaced pointsalong the break .or crack, with the longitudinal axis of eachofthe grooves extending across the break or crack and at substantially right angles to the break or crack. An elongated, variable width metal strip was, inserted in each of the grooves, and the metal strip washammered tightly into-the groove. Thus, the metal strips mechanically secured the sides of the break or crack together. To seal the break or crack, a plurality of holes'were drilled in the metal article, in side-by-side relation along the crack between the metal strips, with the holes extending across the crack. A metal plug was then secured. in each of holes to seal thecrack or break. This method of repairing breaks or cracks in a cast metal articleis .both a complicated and time consuming operation. Furthermore, it has been found that whenthe metal strips are hammered into the grooves, the sides of the breakzorcrack are forced apartso that the break or crack becomes more diflicult toseal. 9 9

It is an object of the present invention to provide a novel device for repairing breaks. or cracks in a cast metal article.

It is another object of the present invention to provide a device for repairing breaks or cracks in a cast metal article which pulls the sides of the break or crack to- 'gether; and which seals the break or crack. dtis still another objectof thepresent invention to provide a metal staple for repairing breaks or cracks in a cast metal article. 9

It is a further object of the present invention to provide a metal staple for repairing breaks or cracks in a cast metalfarticle' which pulls the sides of the break or crack together. 9 9

It is still a'further objectof the present invention to vprovide a device'forquickly and easily repairing cracks or breaks in a cast metal article. Other objects will appear hereinafter; I For the purpose of illustrating the invention there is shown in the drawings formswhich are presently preferred; it being understood, however, thatthis invention is .notlimitedto the precise arrangements. and instrumentalities shown.

- Figure l is a top plan view of acracked, cast metal object partly repaired by the device of..tl 1e present invention.

. U d S s a fi O Figure 2 is a sectional view taken along line 2-2 of Figure 1 showing one stage in the repairing-of the crack in the metal article by the device of the present invention.

Figure 3 is a view similar to Figure 2- showing another stage in the repairing of the crack in the metal article;

Figure 4 is a View similar to Figure 3 showing the final stage in the repairing of thecrack inthe metal article.

Figure 5 is a top plan view similar to Figure 1 showing the crack completely repaired. 9 h 9 99 Figure 6 is a perspective viewof another embodiment of the repair device of the present invention. 99

Figure 7 is a sectional view through a cracked, cast metal article repaired by the embodiment of the repair device of the present invention shown in Figure 6.

Figure 8 is a perspective view ofstill another embodiment of the repair device of the present invention. Figure 9 is a sectional view through a cracked, cast metal article illustrating one stage in the repair of the crack by the repair device shown in Figure 8.

Figure 10 is a view similar to Figure 9 showing the final stage in the repairing of the crack.

Referring initially to Figures 1 and 2, there is shown a portion of a cast metal plate 20 having a crack 22 therein. Plate20 maybe a portion of a piece of machinery, a tank, a pipe, orany other cast metal article. 9

To repair the crack 22 in the plate 20, a hole 24, which is preferably a tapered hole, is drilled in the outer surface of the plate 20 part way through the thickness of the plate 20. Hole 24 is positioned across the crack 22 so that a portion of the hole 24 is 011 both sides of the crack 22. Hole 24 is tapped to provide a thread on the, wall of, the hole 24. A pair of smaller holes 2 6 are drilled-in the bottom surface ofthe tapered hole 24 through the remaining portion of the thickness of the plate 20. Holes 26 are positioned on opposite sides of the crack 22, andare angled toward each other. A washer 928 of a soft metal, such as lead, is positioned in the bottom of the tapered hole 24. Washer 28 has a pair of holes: 30 therethrough which are in alignment with the holes 26 in the bottom of the tapered hole 24. h p A metal staple, generally designated as 32, mechanically connects the sides of the crack 22 together. Staple 32 is U-shaped, havinga base 34, and a pair of legs 36. The base 34of staple 32 is of a length equal to the distance between the holes 26 along the bottom of the tapered hole 24, and the legs 36 of the staple 3 2 are angled toward each other. The legs 36 of staple 32 are inserted through the holes 30 in washer 28 into the holes 2 6, with the base 34 of the staple 32 extending across the crack 22. As the legs 3 6 of staple 32 are forced through the holes 26, the legs 36 engage the walls of the holes 2 6 and cam the sides of the crack 22 together. A tapered, externally threaded, metal plug 38 is threaded into the tapered-hole 24 over the staple 32. As shown in Figure 3, plug 38 is threaded into the tapered hole 24 until the plug 38 engages the base 34 of staple 32, and forces the base 34 tightly against the washer 28. The engagement of the base 34 of staple 32 with the washer 28 forces the Washer 28 tightly against the bottom of the tapered hole 24 to seal the portion of the crack 22 which extends across the hole 24. Thus, the plug '38 secures the staple 32 tightly in place to provide a strong mechanical connection between the sides of the crack 22, and also seats the washer 28 to seal the crack 22. Also, the threaded engagement between the plug 38and the wall of the hole 24provides an additional seal for the crack 22. Since the plug 38 provides a seal for the crack 22, the washer 28 may be left out if desired. However, where the metal plate 20 is part of a tank or pipe containing a material under pres sure, it is preferableto include the washer 28 to insure a tight seal across the crack 22. As shown in Figure -3, the

plug 38 is longer than the depth of the tapered hole 24 to v insure that the plug 38 will completely fill the hole 24 above the staple 32. After the plug 38 is tightly seated in the hole 24 against the base 34 of staple 32, the top end of the plug 38 which projects beyond the outer surface of the plate 20 is removed so that the top surface of the plug 38 is flush with the outer surface of the plate 20' as shown in Figure 4.- a

As shown in Figures 1 and 5, a plurality of the tapered holes 24 are provided in the outer surface of the plate 20 with the holes 24 being in side-by-side, partly overlapping relation along the entire length of the crack 22. Although a staple 32 can be used in each of the holes 24 to secure the sides of the crack 22 together, in certain types of the cast metal articles it may only be necessary to use a staple 32 in every second or third hole 24. The number of the staples 32 which must be used to secure the sides of the crack 22 together depends on the stresses being applied to the plate 20. Thus, if the plate 20 is highly stressed, a staple 32 may be necessary in each of the holes 24. Otherwise, it may only be necessary to use a staple 32 in every second or third hole 24. In the holes 24 in which a staple 342 is not used, a plug 38 is merely threaded tightly into the hole to seal the crack 22. Thus, when the crack 22 is completely repaired, as shown in Figure 5, only the top surfaces of the plugs 38, which are flush with the outer surface of the plate 20, are visible.

Referring to Figures 6 and 7, another embodiment of the staple of the present invention is generally designated as 40. Staple 40 comprises a substantially flat, circular base 42, and a pair of legs 44 extending from one surface of the base 42. The base 42 of the staple 40 is of adiameter substantially equal to the diameter of the hole 24 in the plate 20 at the bottom of the hole 24. The legs 44 of the staple 40 are angled toward each other, and are spaced apart a distance to permit the legs 44 to be inserted through the holes 26 in the bottom of the tapered hole 24.

As shown in Figure 7, the staple 40 is used in the same manner as the staple 32 shown in Figures 2-4 to repair the crack 22 in the plate 20. However, the staple 40 has an advantage over the staple 32 since the base 42 of the staple 40 extends across the entire surface of the metal sealing washer 28. Thus, when the plug 38 is threaded tightly against the base 42 of the staple 40 to force the base 42 against the washer 28, the entire area of the washer 28 will be compressed tightly against the bottom of the tapered hole 24 to insure a tight seal across the crack 22.

When repairing cracks in a thin, cast metal plate by the repair device of the present invention, the tapered holes drilled in the plate may be too shallow to be tapped with suflicient thread to secure a threaded plug 38 in the hole. Figure 8 shows still another embodiment of the staple of the present invention generally designated as 46, for use in repairing cracks in thin, metal plates.

Staple 46 comprises a circular base 48 having a pair of legs 50 extending from one surface of the base 48. The

peripheral surface 52 of the base 48 is tapered, and is of a diameter which conforms with the diameter of a tapered hole 24 in the outer surface of a thin, cast metal plate 20'. The base 48 of staple 46 is of a thickness greater than the depth of the hole 24' so that the base 48 will completely fill'the hole 24. The legs 50 of the staple 46 are angled toward each other.

In the use of the staple 46, the legs 50 are inserted through the holes 30 in a soft malleable metal sealing washer 28, such as one formed of lead, into the holes 26' in the bottom of the hole 24'. The base 48 of the staple 46 is hammered into the hole 24' until the base 48 engages the washer 28 and compresses the washer 28 tightly against the bottom of the hole 24 to seal the crack 22. This also forces the legs 50 of the staple 46 through the holes 26 to pull the sides of the crack 22' tightly together. When the base 48 of the staple 46 is tightly seated in the hole 24', the top portion of the base 48 which projects beyond the outer surface of the plate 20 is removed so that the top surface of the base 48 is substantially flush with the outer surface of the plate 20. The top surface of the base 48 is then peened over the outer surface of the plate '20 around the edge of the hole 24' as shown in Figure 10, to further secure the staple 46 to the plate 20. Thus, the staple 46 not'only mechanically connects the sides of the crack 22', but is also self-secured to the plate 20.

The staple 46 may have parallel legs prior to insertion, with the legs of the staple'46 angling in on the insertion through the angled holes 30. V v

The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof and, accordingly, reference should be made to the appended claims, rather than the foregoing specification as indicating the scope of the invention.

I claim:

1. A repair for a break in a metal plate comprising a hole in the surface of said plate extending part way through the thickness of said plate, said hole extending across the break in said plate so that a portion of the hole is on both sides of the break, a pair of smaller holes in the bottom surface of said first mentioned hole, said smaller holes extending through the remaining portion of the thickness of said plate and being on opposite sides of the break, said smaller holes being angled toward each other, a metal staple having a base and a pair of legs extending from said base, the legs of said staple being angled toward each other, the legs of said staple extending through said smaller holes with the base of said staple being in said first mentioned hole and extending across the break in said plate, and means securing said staple in said holes.

2. A repair in accordance with claim 1 in which the first mentioned hole is threaded, and the means securing the staple in the holes comprises a metal plug threaded in said first mentioned hole and engaging the base of said staple.

3. A repair in accordance with claim 2 in which the staple comprises a generally U-shaped Wire, and the base of the staple is of a length substantially equal to the dis? tance between the smaller holes along the bottom of the first mentioned hole.

4. A repair in accordance with claim 3 in which the first mentioned hole and the plug are tapered.

5. A repair in accordance with claim 2 in whichthe staple comprises a substantially flat, circular base, and the legs of the staple extend from the bottom surface of the base.

6. A repair in accordance with claim 5 in which the first mentioned hole and the plug are tapered.

7. A repair in accordance with claim 1 in which the staple comprises a cylindrical base with the legs extending from the bottom surface of the base, the outer diameter of said base conforming to the diameter of the Wall of the first mentioned hole in the plate, and the thickness of said base being at least equal to the depth. of said first mentioned hole, and means securing the staple in the holes comprises friction fit between the base of said staple and the wall of said first mentioned hole.

8. A repair in accordance with claim 7 in which the first mentioned hole in the plate and the peripheral surface of the base of the staple are tapered.

9. A repair for a break in a metal plate comprising. a hole in the surface of said plate extending part way through the thickness of said plate, said hole extending across the break in said plate so that a portionof said hole is on both sides of the break, a pair of smaller holes in the bottomsurface of said first mentionedhole, said smaller holes extending through the remaining portion of the thickness of said plate and being on opposite sides of the break, said smaller holes being angled toward each other, a metal staple having a base and a pair. of legs extending from said base, the legs of said staple extending through said smaller holes with the base of said staple being in said first mentioned hole and extending across the break in said plate, and means securing said staple in said holes.

10. A repair for a break in the wall of a metal tank or pipe comprising a hole in the surface of said wall extending partway through the thickness of said wall, said hole extending across the break in said Wall so that a portion of the hole is on both sides of the break, a pair of smaller holes in the bottom surface of said first mentioned hole, said smaller holes extending through the remaining portion of the thickness of said wall and being on opposite sides of the break, said smaller holes being angled toward each other, a metal staple having a base and a pair of legs 15 2,252,986

extending from said base, the legs of said staple being angled toward each other, the legs of said staple extending through said smaller holes with the base of said staple being in said first mentioned hole and extending across the break in said plate, a soft metal washer in said first mentioned hole between the bottom of said first mentioned hole and the base of said staple, said washer having a pair of holes therethrough through which the legs of said staple extend, and means securing said staple in said holes and urging the base of said staple against said washer.

References Cited in the file of this patent UNITED STATES PATENTS Scott Aug. 19, 1941 

